0160448en 004

0706

Light Tower

LTC 4L

OPERATOR’S MANUAL

0 1 6 0 4 4 8 E N
LTC 4L Table of Contents
1. Foreword 3

2. Safety Information 4

2.1 Laws Pertaining to Spark Arresters ...................................................... 4

2.2 Operating Safety .................................................................................. 5
2.3 Operator Safety while using Internal Combustion Engines .................. 6
2.4 Service Safety ...................................................................................... 7
2.5 Label Locations .................................................................................... 8
2.6 Safety and Operating Labels .............................................................. 10

3. Technical Data 16

3.1 Engine ................................................................................................ 16

3.2 Generator ........................................................................................... 17
3.3 Machine .............................................................................................. 17

4. Operation 18

4.1 Adjusting Lights .................................................................................. 18

4.2 Operating Lights ................................................................................. 19
4.3 Raising Tower (Manual Winch System) ............................................. 20
4.4 Lowering Tower (Manual Winch System) ........................................... 22
4.5 Control Panels - 50 Hz - Manual Winch System
(0009379, 0009485 Rev. 101 & lower) ............................................... 24
4.6 Control Panels - 50 Hz - Manual Winch System
(0009485 Rev. 102 & higher) ............................................................. 26
4.7 Starting ............................................................................................... 28
4.8 Automatic Shutdown .......................................................................... 28
4.9 Stopping ............................................................................................. 29
4.10 Emergency Stop Switch ..................................................................... 29
4.11 Derating .............................................................................................. 29
4.12 Receptacle - 50 Hz ............................................................................. 30

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Table of Contents LTC 4L
5. Maintenance 31

5.1 Installing / Removing Light Fixtures ....................................................31

5.2 Replacing / Removing Bulbs ...............................................................32
5.3 Daily Inspection ...................................................................................32
5.4 Air Cleaner ..........................................................................................33
5.5 Engine Oil ............................................................................................33
5.6 Engine Maintenance ............................................................................34
5.7 Troubleshooting ...................................................................................35
5.8 Schematic for 50 Hz Metal Halide 4-Light Units-115 V
(0009379 Rev. 104 and higher) ...........................................................36
5.9 Schematic for 50 Hz Metal Halide 4-Light Units-115 V
(0009379 Rev. 102 and 103) ...............................................................38
5.10 Schematic for 50 Hz Metal Halide 4-Light Units-115 V
(0009379 Rev. 101 and lower) ............................................................40
5.11 Schematic for 50 Hz Metal Halide 4-Light Units-230 V
(0009485 Rev. 104 and higher) ...........................................................42
5.12 Schematic for 50 Hz Metal Halide 4-Light Units-230 V
(0009485 Rev. 102 and103) ................................................................44
5.13 Schematic for 50 Hz Metal Halide 4-Light Units-230 V
(0009485 Rev. 101 and lower) ............................................................46
5.14 Generator Capacitor Excitation Schematic 50 Hz ...............................48
5.15 Engine Wiring - Lombardini .................................................................49
5.16 Control Panel Wiring ...........................................................................50

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 CALIFORNIA
Proposition 65 Warning:
Engine exhaust, some of its constituents, and certain vehicle
components, contain or emit chemicals known to the State of
WARNING
California to cause cancer and birth defects or other reproductive
harm.

1. Foreword
This manual provides information and procedures to safely operate
and maintain this Wacker model. For your own safety and protection
from injury, carefully read, understand and observe the safety
instructions described in this manual.

Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Corporation.

The information contained in this manual was based on machines in

production at the time of publication. Wacker Corporation reserves the
right to change any portion of this information without notice.

All rights, especially copying and distribution rights, are reserved.

Copyright 2006 by Wacker Corporation.

No part of this publication may be reproduced in any form or by any

means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.

Any type of reproduction or distribution not authorized by Wacker

Corporation represents an infringement of valid copyrights and will be
prosecuted. We expressly reserve the right to make technical
modifications, even without due notice, which aim at improving our
machines or their safety standards.

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Safety Information LTC 4L
2. Safety Information
This manual contains DANGER, WARNING, CAUTION, and NOTE
callouts which must be followed to reduce the possibility of personal
injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury.
DANGER

WARNING indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.
WARNING

CAUTION indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury.
CAUTION
CAUTION: Used without the safety alert symbol, CAUTION indicates
a potentially hazardous situation which, if not avoided, may result in
property damage.

Note: Contains additional information important to a procedure.

2.1 Laws Pertaining to Spark Arresters

Notice: State Health Safety Codes and Public Resources Codes

specify that in certain locations spark arresters be used on internal
combustion engines that use hydrocarbon fuels. A spark arrester is a
device designed to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified and rated by
the United States Forest Service for this purpose.
In order to comply with local laws regarding spark arresters, consult
the engine distributor or the local Health and Safety Administrator.

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LTC 4L Safety Information
2.2 Operating Safety

Familiarity and proper training are required for the safe operation of
equipment. Equipment operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both
WARNING this manual and the engine manual and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the equipment before
being allowed to operate the machine.
2.2.1 The area immediately surrounding the Light Tower should be clean,
neat, and free of debris.
2.2.2 ALWAYS be sure the machine is on a firm, level surface and will not
tip, roll, slide, or fall while operating.
2.2.3 NEVER start a unit in need of repair.
2.2.4 Lower the tower when not in use, or if high winds or electrical storms
are expected in the area.
2.2.5 The tower extends up to 8.8 m (29 ft.). Make sure area above trailer is
open and clear of overhead wires and obstructions.
2.2.6 The bulbs become extremely hot in use! Allow the bulb and fixture to
cool 10–15 minutes before handling.
2.2.7 Keep the area behind the trailer clear of people while raising and
lowering the mast! Never raise, lower or turn the mast while unit is
operating!
2.2.8 The trailer must be leveled and the outriggers extended before raising
the tower. The outriggers must remain extended while the tower is up.
2.2.9 If for any reason any part of the mast hangs up or the winch cable
develops slack while raising or lowering the tower, STOP immediately!
Contact an authorized WACKER service representative.
2.2.10 NEVER remove the mast locking pin while the tower is up!
2.2.11 NEVER use the machine if the insulation on the electrical cord is cut or
worn through.
2.2.12 NEVER operate the lights without the protective lens cover in place or
with a lens cover that is cracked or damaged!
2.2.13 NEVER adjust the mast while the unit is operating.
2.2.14 NEVER raise the mast or operate the Light Tower in high winds.
2.2.15 NEVER connect machine to other power sources, such as supply
mains of power companies.
2.2.16 ALWAYS replace or repair electrical components with components
that are identical in rating and performance as the original component.

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Safety Information LTC 4L
2.3 Operator Safety while using Internal Combustion Engines

Internal combustion engines present special hazards during operation

and fueling. Read and follow the warning instructions in the engine
owner’s manual and the safety guidelines below. Failure to follow the
DANGER warnings and safety guidelines could result in severe injury or death.
2.3.1 NEVER operate the machine indoors unless exhaust fumes can be
adequately ventilated.
2.3.2 DO NOT fill or drain the fuel tank near an open flame, while smoking,
or while the engine is running.
2.3.3 ALWAYS refill the fuel tank in a well-ventilated area.
2.3.4 DO NOT touch or lean against hot exhaust pipes.
2.3.5 ALWAYS replace the fuel tank cap after refueling.
2.3.6 DO NOT remove radiator cap when the engine is running or hot. The
radiator fluid is hot and under pressure and may cause severe burns!
2.3.7 DO NOT use gasoline or other types of fuels or flammable solvents to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
2.3.8 ALWAYS keep the area around the muffler free of debris such as
leaves, paper, cartons, etc. A hot muffler could ignite the debris and
start a fire.

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LTC 4L Safety Information
2.4 Service Safety

HIGH VOLTAGE! This unit uses high voltage circuits capable of

causing serious injury or death. Only a qualified electrician should
troubleshoot or repair electrical problems occurring in this equipment.
WARNING

2.4.1 ALWAYS replace the safety devices and guards after repairs and
maintenance.
2.4.2 Before servicing the Light Tower, make sure the engine start switch is
turned to OFF, the circuit breakers are open (off), and the negative
terminal on battery is disconnected. NEVER perform even routine
service (oil/filter changes, cleaning, etc.) unless all electrical
components are shut down.
2.4.3 DO NOT allow water to accumulate around the base of the machine.
If water is present, move the machine and allow the machine to dry
before servicing.
2.4.4 DO NOT service the machine if your clothing or skin is wet.
2.4.5 ALWAYS keep hands, feet, and loose clothing away from the moving
parts on the generator and engine.
2.4.6 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
2.4.7 ALWAYS make sure slings, chains, hooks, ramps, jacks and other
types of lifting devices are attached securely and have enough weight-
bearing capacity to lift or hold the machine safely. Always remain
aware of the location of other people around when lifting the machine.
2.4.8 ALWAYS turn off the light circuit breakers and shut down the engine
before disconnecting the light fixtures or changing the light bulbs.

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Safety Information LTC 4L
2.5 Label Locations

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LTC 4L Safety Information

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Safety Information LTC 4L
2.6 Safety and Operating Labels

Wacker machines use international pictorial labels where needed.

These labels are described below:

Ref. Label Meaning

A DANGER!
A non-secured, falling mast will cause
serious injury or death if a person is hit.
To secure mast, verify automatic locking
pin has engaged to secure tower upright.

B WARNING!
Avoid crushing area.

C WARNING!
Completely lower tower before tilting
mast. Tilting an extended mast could
cause serious injury or death.

D DANGER!
Contact with overhead electrical power
lines will cause serious injury or death.
Do not position Light Tower under
electrical power lines.

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LTC 4L Safety Information
Ref. Label Meaning
E CAUTION!
Lifting point

F WARNING!
Secure mast in transport lock before
lifting or towing. A loose swinging mast
could cause personal injury or machine
damage.

G DANGER!
Asphyxiation hazard. Read the Opera-
tor’s Manual for instructions. No sparks,
flames, or burning objects near machine.
Stop the engine before adding fuel. Use
only diesel fuel.

H DANGER!
Asphyxiation hazard. Read the Opera-
tor’s Manual for instructions. No sparks,
flames, or burning objects near machine.
Stop the engine before adding fuel. Use
only diesel fuel.

DANGER!
Contact with overhead electrical power
lines will cause serious injury or death.
Do not position Light Tower under
electrical power lines.

WARNING!
Completely lower tower before tilting
mast. Tilting an extended mast could
cause serious injury or death.

I DANGER!
Electrical storage device within. Contact
a qualified electrician for service or to
open electrical box. Electric shock will
cause serious injury or death.

wc_si000146gb.fm 11
Safety Information LTC 4L
Ref. Label Meaning
K WARNING!
Stand clear of front and rear of machine
when mast is being tilted up or down.

L WARNING!
Hot surface!

M A nameplate listing the model number,

item number, revision number, and serial
number is attached to each unit. Please
record the information found on this plate
so it will be available should the
nameplate become lost or damaged.
When ordering parts or requesting
service information, you will always be
asked to specify the model number, item
number, revision number, and serial
number of the unit.

N WARNING!
Ultraviolet radiation from lamp can cause
serious skin and eye irritation. Use only
with provided undamaged lens cover and
fixture.

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LTC 4L Safety Information
Ref. Label Meaning
O

wc_si000146gb.fm 13
Safety Information LTC 4L
Ref. Label Meaning
Q
Manual Winch System

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LTC 4L Safety Information
Ref. Label Meaning
R Coolant overflow bottle only, not a return
system.

S WARNING!
Pinching hazard. Rotating machinery.

T Guaranteed sound power level in dB(A)

U DO NOT pressure wash the control

panel.

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Technical Data LTC 4L
3. Technical Data

3.1 Engine

Item Number: LTC 4L - 115V LTC 4L - 230V

0009379 0009485

Engine
Make Lombardini
Model LDW1003
Type 3-cylinder, 4-cycle, liquid-cooled diesel
Maximum power rating kW (Hp) 8.5 (11.4)
Operating power rating kW (Hp) 7.6 (10.2)
Operating speed
rpm 1500
(no-load)
Alternator V/A/W 12 / 45 / 540
Battery V/Ah/CCA 12 / 450
Air cleaner type dry-type element
Fuel type No. 2 diesel
Fuel tank capacity l (gal.) 114 (30)
Fuel consumption l (gal.) / hr. 1.71 (0.45)
Running time hours 67.7
Coolant capacity l (qts.) 4.7 (5.0)
Oil capacity l (qts.) 2.4 (2.5)
Oil weight SAE 15W40 CD or higher

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LTC 4L Technical Data
3.2 Generator

Item Number: LTC 4L - LTC 4L - LTC 4L - LTC 4L -

115V 115V 230V 230V
0009379 0009379 0009485 0009485
Rev. 104 Rev. 103 Rev. 104 Rev. 103
and higher and lower and higher and lower

Generator
Frequency Hz 50 ± 2
Continuous output kW 6.0 5.0 6.0 5.0
Output volts 115 230
Amps A 43.5 21.7
Excitation type Capacitor / Brushless
Power factor 1.0
Voltage regulation -
% ± 5.0
no load to full load
Speed rpm 1500

3.3 Machine

Item Number: LTC 4L - 115V LTC 4L - 230V

0009379 0009485

Machine
Height - mast extended m (ft.) 8.8 (29)
Lighting system
4 metal halide light
(1000W)
Max. lighting coverage m2 (ft2) 2824 (30,400)
@ 0.5 ft. candles acres 7
Sound level at 7 m dB(A)
67
(23 ft.)
Sound pressure level at dB(A)
operator's location (LpA) 91

Guaranteed sound dB(A)

power level (LWA) 97

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Operation LTC 4L
4. Operation

4.1 Adjusting Lights

See Graphic: wc_gr002090

Each light fixture can be aimed up, down, left or right. Position each
fixture by loosening toolless light adjusters (g) and aiming light up or
down. Do not loosen inside nut (x). Loosening this nut can damage the
light fixture. Loosen nut (h) to turn light fixtures left or right. Tighten
adjusters and nuts after positioning lights.
Always return light fixtures to aim up or away from the ground when
mast is in the cradle for towing.

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LTC 4L Operation
4.2 Operating Lights

See Graphic: wc_gr002934

Turn on circuit breaker (a) first, then turn each circuit breaker (b) “ON”,
one at a time.
Metal halide floodlights require a warm-up of 5–15 minutes before they
reach full output. If floodlights are shut down, a 10-minute cool-down
period is required before turning them back on.

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Operation LTC 4L
4.3 Raising Tower (Manual Winch System)

See Graphic: wc_gr002166

NEVER raise the mast or operate the Light Tower in high winds.
NEVER raise the mast while the engine is running.
WARNING

HIGH VOLTAGE! DO NOT use the Light Tower if insulation on

electrical cord is cut or worn through. Repair or replace the cord before
WARNING using. Bare wires in contact with the metal frame of the trailer or tower
can cause electrocution.
DO NOT position the Light Tower under electrical power lines.

NEVER allow anyone to stand near the rear of the unit while raising the
mast.
WARNING
The Light Tower includes two separate winches. One for lifting the
mast to the vertical position, the other for raising the tower. Each winch
is an automatic brake-type winch that automatically brakes when the
handle is released. The handle must be rotated to wind in cable as well
as unwind cable.

NEVER touch the winch pawl! Releasing the pawl may cause the
mast or tower to fall.
WARNING

4.3.1 Check winch cables (n) for wear or damage, and make sure they are
resting properly in pulleys. Do not use the Light Tower if either winch
cable is damaged.
4.3.2 Remove the cradle locking pin (j) from the cradle.
4.3.3 Check the operation of the tongue-mounted winch (o) by rotating the
winch handle 1/4-turn clockwise (“cable in” direction). The winch pawl
must engage winch gear teeth. When operating properly, the winch
pawl will make a “clicking” sound when the winch handle is rotated
clockwise. Do not attempt to raise the mast if the winch is damaged or
not operating properly.
4.3.4 Continue to rotate the winch handle and raise the mast to the vertical
position until the vertical mast locking pin (p) locks the mast in place.
Be certain the vertical mast locking pin is fully engaged in the locking
position before raising the tower.

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LTC 4L Operation

NEVER pull the vertical mast locking pin (p) while the tower is
raised! Releasing the vertical mast locking pin while the tower is
WARNING raised may cause the tower to fall or the machine to tip over.
4.3.5 After the mast is in the vertical position, check the operation of the
mast-mounted winch (q) by rotating the winch handle 1/4-turn
clockwise (“cable in” direction). The winch pawl must engage winch
gear teeth. When operating properly, it will make a “clicking” sound
when the winch handle is rotated clockwise. Do not attempt to raise the
mast if the winch is damaged or not operating properly. Continue
rotating the winch handle until mast is at the desired height. Do not
over crank the winch when the tower is fully extended.
CAUTION: Do not extend the tower beyond the red marking on the
mast!
4.3.6 Once the tower is at the desired height, rotate the mast to the desired
direction. To rotate, loosen rotation locking knob (s). Then using the
handle (u), rotate the mast until the lights face the desired direction,
and then retighten the rotation locking knob.

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Operation LTC 4L
4.4 Lowering Tower (Manual Winch System)

See Graphic: wc_gr002166

Be sure to read and understand the operating instructions before
lowering the tower!
If for any reason a part of the mast hangs up or a winch cable develops
slack before mast is fully lowered, stop immediately! Continuing to
turn the winch handle will increase the slack in the cable. Too much
WARNING
slack could cause the mast to collapse should it suddenly free up. If the
mast hangs up, level the trailer. Slightly shake or twist the tower
assembly to free the bind. Contact an authorized WACKER service
representative immediately.

NEVER lower the mast while the unit is operating.

WARNING

NEVER allow anyone to stand near the rear of the unit while lowering
the mast.
WARNING

4.4.1 Turn the lights off. Shut down the engine.

CAUTION: Shutting down the engine before turning off the lights could
damage floodlight ballasts or generator capacitor(s).
CAUTION: Observe power cord while lowering the tower. Make sure
the coiled cord is not damaged during the lowering process.
4.4.2 Lower the tower by turning the handle on the mast-mounted winch (q)
counterclockwise (“cable out” direction).

NEVER touch the winch pawl! Releasing the winch pawl may cause
the mast or tower to fall.
WARNING

4.4.3 Loosen the rotation locking knob (s) and using the handle (u), rotate
the mast so the lights face the rear of the trailer and the mast-mounted
winch is facing toward the trailer tongue.

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LTC 4L Operation
4.4.4 Pull and hold the mast locking pin (p). Rotate the handle on the tongue-
mounted winch (o) counterclockwise (“cable out” direction) until the
mast spring begins to pivot the mast down. Release the mast locking
pin and continue to rotate the handle until the mast is resting in the
transport cradle. Be sure that the secondary locking pin (t) penetrates
all sections of the mast.

NEVER pull the vertical mast locking pin (e) while the tower is
raised! Releasing the locking pin while the tower is raised may cause
WARNING the tower to fall or the machine to tip over.

4.4.5 After the mast is down, secure it in the cradle by inserting the cradle
lock pin (j). Insert the clip through the pin to secure it in place.
4.4.6 Position the light fixtures to aim at the ground.
CAUTION: Allow the floodlights to cool 10–15 minutes before moving
trailer. Moving the trailer while the lights are still hot could cause the
bulbs to break.

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Operation LTC 4L
4.5 Control Panels - 50 Hz - Manual Winch System (0009379,
0009485 Rev. 101 & lower)

Floodlight Control Panel Engine Control Panel

t
ERGENC
M
Y
E

wc_gr002294

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LTC 4L Operation

Ref. Description Ref. Description

a 50 Amp circuit breaker l Alternator Indicator
b 15 Amp lights circuit breaker m Auxiliary lights (not used)
c 20 Amp GFI circuit breaker n Glow Plug Indicator
d Receptacle o Air Filter Restriction Indicator
e Hour Meter p Auxiliary lights (not used)
f Low Fuel Indicator (not used) q Key Access Door
g Safety Shutdown Indicator r 25 Amp Earth-leakage circuit breaker
h Low Oil Pressure Shutdown t Emergency stop switch
k High Coolant Temperature Shutdown

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Operation LTC 4L
4.6 Control Panels - 50 Hz - Manual Winch System (0009485 Rev.
102 & higher)

Floodlight Control Panel Engine Control Panel

t
ERGENC
M
Y
E

wc_gr002294

Note: On machine Revisions 102 and higher, the generator neutral

wire is not connected to the frame ground or Potential Earth (PE). Be
informed that this machine is wired with an IT Network. Before
connecting this machine to a distribution system, you must consult with
a local electrician for wiring codes.

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LTC 4L Operation

Ref. Description Ref. Description

a 50 Amp circuit breaker k High Coolant Temperature Shutdown
b 15 Amp lights circuit breaker l Alternator Indicator
c 20 Amp GFI circuit breaker m Auxiliary lights (not used)
d Receptacle n Glow Plug Indicator
e Hour Meter o Air Filter Restriction Indicator
f Low Fuel Indicator (not used) p Auxiliary lights (not used)
g Safety Shutdown Indicator q Key Access Door
h Low Oil Pressure Shutdown t Emergency stop switch

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Operation LTC 4L
4.7 Starting

See Graphic: wc_gr002293, wc_gr0002294

4.7.1 Check engine oil, fuel and coolant levels.
Note: If fuel tank was drained or run dry it may be necessary to bleed
fuel lines. Refer to Engine Operator’s Manual.
4.7.2 Check condition of electrical cable on mast. Do not start generator if
insulation on cable is cut or worn through.
4.7.3 Check that the circuit breakers (a, b, c) are in their “OFF” position.
4.7.4 Check that the emergency stop switch (t) is pulled out.
CAUTION: Starting engine under load will damage the machine.
4.7.5 On machines equipped with the Lombardini engine, turn key (q) one
click right. Glow plug indicator (n) will illuminate until engine is properly
preheated. This is an automatic timer based on engine temperature.
Crank engine immediately after glow plug light goes off.
4.7.6 Turn key (q) to “START” and hold until engine starts. Release key after
engine starts.
CAUTION: Do not crank engine longer than 10 seconds. This could
cause starter motor to overheat. Return switch to “OFF” and wait 15-
30 seconds for starter motor to cool down before attempting to preheat
and restart.
Note: If oil pressure is not obtained within 30 seconds after key is
turned to “RUN”, the automatic shutdown system will shut off the fuel
supply. You must return the key to the “OFF” position to restart the 30
second timer before attempting to restart the engine.
4.7.7 Allow engine to warm up before operating floodlights.
CAUTION: Never use starting fluids to aid in starting of engine.

4.8 Automatic Shutdown

This unit is equipped with a low oil, high temperature auto-shutdown

system. This system will automatically shut off the fuel supply to the
engine if the oil pressure drops too low or the engine exceeds normal
operating temperatures. Return the key switch to “OFF” to reset the
unit after an engine shutdown.

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LTC 4L Operation
4.9 Stopping

See Graphic: wc_gr002293

4.9.1 Turn the circuit breakers (a, b, c) off and remove any other loads from
the generator.
CAUTION: Never shut down the engine without turning off the lights.
Damage to the generator will occur.
4.9.2 Turn the key (q) to OFF.

4.10 Emergency Stop Switch

See Graphic: wc_gr002294

In case of emergency, push in the emergency stop switch (t) located
on the front panel.

4.11 Derating

All generator sets are subject to derating for altitude and temperature.
Although derating should not affect operation of the floodlights, it will
reduce the available reserve power to the receptacle.
Ratings are typically reduced 3% per 300 m (1000 feet) elevation from
sea level, and 2% per 10°F (5.5°C) increase in ambient temperature
above 78°F (25°C).

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Operation LTC 4L
4.12 Receptacle - 50 Hz

See Graphic: wc_gr002293, wc_gr002294

The machine is equipped with a convenience receptacle for running
accessories and tools from the generator. Power to this receptacle is
available any time the engine is running and the circuit breaker is “ON”.
CAUTION: With the lights on, do not draw more than 400 Watts from
the 115V receptacle or 800 Watts from the 230V receptacle.
A circuit breaker (c) protects the receptacle (d).
CAUTION: Do not use frayed or damaged cords or plugs with auxiliary
outlet.
CAUTION: Use only tough rubber-sheathed flexible cable or
equivalent. (per 1EC245-4).
CAUTION: When using extension cords or mobile distribution
networks the total length of cords for a cross section of 1.5 mm2 should
not exceed 60 m. For a cross section of 2.5 mm2, it should not exceed
100 m.

Note: On machine Revisions 102 and higher, the generator neutral

wire is not connected to the frame ground or Potential Earth (PE). Be
informed that this machine is wired with an IT Network. Before
connecting this machine to a distribution system, you must consult with
a local electrician for wiring codes.

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LTC 4L Maintenance
5. Maintenance

5.1 Installing / Removing Light Fixtures

See Graphic: wc_gr002296

ALWAYS turn off light circuit breakers and shut down engine before
disconnecting light fixtures or changing light bulbs.

WARNING
Remove fixtures by disconnecting electrical cords using the quick
disconnects (a) or by disconnecting electrical cords at the junction box
(b). Remove nuts (c) from fixture mounting brackets and remove both
fixture and bracket off stud.
CAUTION: Only a trained technician should be allowed to install and
remove fixture wiring.
Note: When reinstalling the lamp fixtures, make sure the drain hole is
pointing down.
Bulbs become extremely hot in use! Allow bulb and fixture to cool
10-15 minutes before handling.
WARNING
Numbering Sequence of Floodlights Junction Box Wiring for Floodlights

Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light blue

wc_tx000417gb.fm 31
Maintenance LTC 4L
5.2 Replacing / Removing Bulbs

The Light Tower uses four 1000W bulbs. When replacing or removing
the bulbs, avoid leaving any grease or oil residue on the glass surface.
This can create hot spots, reducing the service life of the bulb or
causing the outer jacket to burst.

ALWAYS turn off the light circuit breakers and shut down the engine
before disconnecting the light fixtures or changing the light bulbs.
WARNING Bulbs become extremely hot in use! Allow the bulb and fixture to
cool 10–15 minutes before handling.

NEVER operate the lights without the protective lens cover in

place or with a lens cover that is cracked or damaged! The lamps
used in the floodlights produce high temperatures and operate under
WARNING pressure. They are subject to failures where the outer jacket bursts
and shatters, resulting in a discharge of extremely hot glass particles.
These particles pose a risk of personal injury, property damage, burns
and fire.

Ultraviolet radiation from the lamp can cause serious skin and eye
irritation. Use the lamp only with provided undamaged lens cover and
WARNING
fixture.

5.3 Daily Inspection

5.3.1 Check for fluid leaks. Check fluid levels.

5.3.2 Inspect condition of electrical cords. Do not use light tower if insulation
is cut or worn through.
5.3.3 Check that winch cables are in good condition. Do not use a cable that
is kinked or starting to unravel.
5.3.4 Check that the vertical mast locking pin and its spring are secured,
aligned, and operating properly.

wc_tx000417gb.fm 32
LTC 4L Maintenance
5.4 Air Cleaner

See Graphic: wc_gr000540, wc_gr002293

Replace the air filter cartridge when the indicator (o) mounted on the
control panel appears.
5.4.1 Open air cleaner and remove element.
5.4.2 To clean the filter, lightly tap on a hard surface to eliminate all excess
dirt. Do not blow the paper filter element with compressed air to clean.
Clean the filter cover and support carefully.
5.4.3 Reassemble the filtering element and air cleaner.

wc_gr000540

5.5 Engine Oil

See Graphic: wc_gr000541

Drain the oil while the engine is still warm.
Note: In the interests of environmental protection, place a plastic sheet
and a container under the machine to collect any liquid which drains
off. Dispose of this liquid in accordance with environmental protection
legislation.
5.5.1 Remove the oil drain plug.
5.5.2 Allow the oil to drain.
5.5.3 Install the oil drain plug.
5.5.4 Fill the engine crankcase through the oil filler opening, to the upper
mark on the dipstick. See Technical Data for oil quantity and type.
5.5.5 Install the oil filter cap.

wc_gr000541

wc_tx000417gb.fm 33
Maintenance LTC 4L
5.6 Engine Maintenance

Before Every Every Every Every

each 125 250 500 1000 hours
use hours hours hours or two years

Check for fluid leaks. „

Check engine oil. „

Check fuel level. „

Replace air filter if indicator light is on.** „

Change engine oil.* „

Check level of battery electrolyte. „

Check condition and tension on fan belt. „

Check condition of radiator hoses. „

Replace oil filter.* „

Replace fuel filter. „

Flush radiator. „

Replace fan belt. „

Check valve clearance. „

Remove sediment in fuel tank. „

Change radiator coolant. „

Replace battery. „

Replace radiator hoses and clamps. „

Replace fuel pipes and clamps. „

* Change engine oil and filter after first 50 hours of operation.

** Replace air filter after air filter restriction switch indication or one year. Lombardini does not
recommend the removal of air filter elements for purposes of inspection.

wc_tx000417gb.fm 34
LTC 4L Maintenance
5.7 Troubleshooting

HIGH VOLTAGE! This unit uses high voltage circuits capable of

causing serious injury or death. Only a qualified electrician should
troubleshoot or repair electrical problems occurring in this equipment.
WARNING

Problem / Symptom Reason / Remedy

Lamp will not start • Lamp is too hot. Allow lamp to cool 10–15 minutes
before restarting.
• Faulty lamp connection. Check that lamp is tight in
socket. Check connections inside connection boxes
on light fixtures and mast.
• Plug connection at fixture is loose or damaged.
• Lamp broken. Check for broken arc tube or outer
lamp jacket, broken or loose components in lamp
envelope, blackening or deposits inside lamp tube.
• Circuit breaker loose or defective.
• Generator output incorrect. Check incoming voltage
to ballast. Incoming voltage should be 120V ± 5V. If
voltage is incorrect, engine speed may need to be
adjusted or generator may require service.
• Low or no ballast output. With the fixture cord
removed from its receptacle, the voltage should
measure 400 to 445 VAC. If proper voltage is not
achieved, perform capacitor check to determine if
capacitor or coil needs to be replaced.
Low Light Output • Lamp worn. Replace lamp due to normal lamp life.
• Low ballast output. Check ballast for proper voltage
output.
• Fixture or lens dirty. Clean reflective surface inside
fixture and both inside and outside surface of glass
lens.

wc_tx000417gb.fm 35
Maintenance LTC 4L
5.8 Schematic for 50 Hz Metal Halide 4-Light Units-115 V (0009379
Rev. 104 and higher)

wc_tx000417gb.fm 36
LTC 4L Maintenance

Ref. Description Ref. Description

a Generator j Junction box

b Terminal strip k Hour meter
c Main circuit breaker, 25 Amp l Transformer
d Floodlight receptacles m Capacitor, 525V
e Receptacle, 115V n Ballasts
f Circuit breaker, 20 Amp r Emergency stop switch
g Circuit breaker, 15 Amp s Solenoid
i Engine control panel t Capacitor, 450V

Note: On machine Revisions 102 and higher, the generator neutral

wire is not connected to the frame ground or Potential Earth (PE). Be
informed that this machine is wired with an IT Network. Before
connecting this machine to a distribution system, you must consult with
a local electrician for wiring codes.

Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light blue

wc_tx000417gb.fm 37
Maintenance LTC 4L
5.9 Schematic for 50 Hz Metal Halide 4-Light Units-115 V (0009379
Rev. 102 and 103)

P1 P2 P3

Gr

Y/B
Or/B

Gr

Y/B
Or/B

Gr

Y/B
Or/B

Gr

Y/B
Or/B

D+
Or
B+ W

wc_gr003237

wc_tx000417gb.fm 38
LTC 4L Maintenance

Ref. Description Ref. Description

a Generator j Junction box

b Terminal strip k Hour meter
c Main circuit breaker l Transformer
d Floodlight receptacles m Capacitor
e Receptacle, 115V n Coil cord
f Circuit breaker, 20 Amp r Emergency stop switch
g Circuit breaker, 15 Amp s Fuel solenoid
i Engine control panel t Alternator

Note: On machine Revisions 102 and higher, the generator neutral

wire is not connected to the frame ground or Potential Earth (PE). Be
informed that this machine is wired with an IT Network. Before
connecting this machine to a distribution system, you must consult with
a local electrician for wiring codes.

Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light blue

wc_tx000417gb.fm 39
Maintenance LTC 4L
5.10 Schematic for 50 Hz Metal Halide 4-Light Units-115 V (0009379
Rev. 101 and lower)

P3 P2 P1

Gr

Y/B
Or/B

Gr

Y/B
Or/B

Gr

Y/B
Or/B

Gr

Y/B
Or/B

D+
Or
B+ W

wc_tx000417gb.fm 40
LTC 4L Maintenance

Ref. Description Ref. Description

a Generator j Junction box

b Terminal strip k Hour meter
c Main circuit breaker l Transformer
d Floodlight receptacles m Capacitor
e Receptacle, 115V n Coil cord
f Circuit breaker, 20 Amp p Earth-leakage circuit breaker, 25
Amp
g Circuit breaker, 15 Amp r Emergency stop switch
h Quick disconnect plugs s Fuel solenoid
i Engine control panel t Alternator

Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light blue

wc_tx000417gb.fm 41
Maintenance LTC 4L
5.11 Schematic for 50 Hz Metal Halide 4-Light Units-230 V (0009485
Rev. 104 and higher)

wc_tx000417gb.fm 42
LTC 4L Maintenance

Ref. Description Ref. Description

a Generator j Junction box

b Terminal strip k Hour meter
c Main circuit breaker, 25 Amp l Transformer
d Floodlight receptacles m Capacitor, 525V
e Receptacle, 115V n Ballasts
f Circuit breaker, 20 Amp r Emergency stop switch
g Circuit breaker, 15 Amp s Solenoid
i Engine control panel t Capacitor, 450V

Note: On machine Revisions 102 and higher, the generator neutral

wire is not connected to the frame ground or Potential Earth (PE). Be
informed that this machine is wired with an IT Network. Before
connecting this machine to a distribution system, you must consult with
a local electrician for wiring codes.

Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light blue

wc_tx000417gb.fm 43
Maintenance LTC 4L
5.12 Schematic for 50 Hz Metal Halide 4-Light Units-230 V (0009485
Rev. 102 and103)

P3 P2 P1

Gr

Y/B
Or/B

Gr

Y/B
Or/B

Gr

Y/B
Or/B

Gr

Y/B
Or/B

12

D+
Or
B+ W

wc_tx000417gb.fm 44
LTC 4L Maintenance

Ref. Description Ref. Description

a Generator i Auxiliary connection of engine con-

trol panel
b Terminal strip j Junction box
c Main circuit breaker k Hour meter
d Floodlight receptacles l Transformer
e 230 V Receptacle m Capacitor
f 20 Amp circuit breaker n Coil cord
g 15 Amp circuit breaker r Emergency stop switch
h Quick disconnect plugs s Fuel solenoid

Note: On machine Revisions 102 and higher, the generator neutral

wire is not connected to the frame ground or Potential Earth (PE). Be
informed that this machine is wired with an IT Network. Before
connecting this machine to a distribution system, you must consult with
a local electrician for wiring codes.

Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light blue

wc_tx000417gb.fm 45
Maintenance LTC 4L
5.13 Schematic for 50 Hz Metal Halide 4-Light Units-230 V (0009485
Rev. 101 and lower)

P3 P2 P1

Gr

Y/B
Or/B

Gr

Y/B
Or/B

Gr

Y/B
Or/B

Gr

Y/B
Or/B

D+
Or
B+
W

wc_tx000417gb.fm 46
LTC 4L Maintenance

Ref. Description Ref. Description

a Generator j Junction box

b Terminal strip k Hour meter
c Main circuit breaker l Transformer
d Floodlight receptacles m Capacitor
e Receptacle, 230V n Coil cord
f Circuit breaker, 20 Amp p Earth-leakage circuit breaker, 25
Amp
g Circuit breaker, 15 Amp r Emergency stop switch
h Quick disconnect plugs s Fuel solenoid
i Engine control panel t Alternator

Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light blue

wc_tx000417gb.fm 47
Maintenance LTC 4L
5.14 Generator Capacitor Excitation Schematic 50 Hz

P3

P2

P1

Ref. Description Ref. Description

1 Rotor 4 Capacitor
2 Stator 5 Generator/Terminal block
3 Excitation coils 6 Control box-Main circuit breaker

wc_tx000417gb.fm 48
LTC 4L Maintenance
5.15 Engine Wiring - Lombardini

Ref. Description Ref. Description

1 Fuel Solenoid 7 Air Filter Restriction Indicator
(normal open type)
2 Glow Plugs 8 Low Fuel Level Switch (not used, nor-
mal open type)
3 Starter Motor 9 Low Oil Pressure Switch
(normal closed type)
4 Battery 10 Coolant High Temperature Switch
(normal open type)
5 Alternator Connector 11 Coolant Temperature Thermistor (for
preheat relay)
6 Coolant Temperature Sending Unit
(not used, for remote temperature
gauge or LED)

wc_tx000417gb.fm 49
Maintenance LTC 4L
5.16 Control Panel Wiring

1 B
2
L 30
86
87
2
85
3
W/R 1
4
Or Y/G

5
B R
6
Pr
7 R
8
Gr
9 W
10
R
4 2
7 6 5 3
12 10 9
11 L
12 P
13
Br 4
50

15
Y/G

/5
14

4
B 30

G B
Br
5

wc_gr000658

Ref. Description Ref. Description

1 System fuse, 50 Amp 4 Key switch
2 Glowplug load relay 5 L.E.D. Indicator lamp assembly
3 Auxiliary terminals (rear view)

wc_tx000417gb.fm 50
 EC DECLARATION OF CONFORMITY
CE-KONFORMITÄTSERKLÄRUNG
DECLARACIÓN DE CONFORMIDAD DE LA CE
DÉCLARATION DE CONFORMITÉ C.E.

WACKER CORPORATION, N92 W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA
AUTHORIZED REPRESENTATIVE IN THE EUROPEAN UNION WACKER CONSTRUCTION EQUIPMENT AG
BEVOLLMÄCHTIGTER VERTRETER FÜR DIE EUROPÄISCHE GEMEINSCHAFT
REPRESENTANTE AUTORIZADO EN LA UNIÓN EUROPEA
Preußenstraße 41
REPRÉSENTANT AGRÉÉ AUPRÈS DE L’UNION EUROPÉENNE 80809 München
hereby certifies that the construction equipment specified hereunder / bescheinigt, daß das Baugerät / certifica que la máquina de
construcción / atteste que le matériel :

1. Category / Art / Categoría / Catégorie

Power Generators (Light Towers)
Kraftstromerzeuger (Beleuchtungsanlagen)
Grupos Electrógenos (Torres de Iluminación)
Groupe Électrogènes de Puissance (Tours d’éclairage)
2. Type - Typ - Tipo - Type
LTC 4L

3. Item number of equipment / Artikelnummer / Número de referencia de la máquina / Numéro de référence du matériel :

0009379, 0009485
4. Electric power / Elektrische Leistung / Potencia eléctrica / Force motrice :
6,0 kW

Has been sound tested per Directive 2000/14/EC / In Übereinstimmung mit Richtlinie 2000/14/EG bewertet worden ist / Ha sido
ensayado en conformidad con la norma 2000/14/CE / A été mis à l’épreuve conforme aux dispositions de la directive 2000/14/CEE :

Conformity Assessment Procedure Name and address of notified Measured sound power level / Guaranteed sound power level /
/ Konformitätsbewertungsverfahren body / Bei folgender Gemessener Schallleistungspegel / Garantierter Schallleistungspegel /
/ Procedimiento para ensayar einbezogener Prüfstelle / Nivel de potencia acústica Nivel de potencia acústica
conformidad / Procédé pour Oficina matriculadora / determinado / Niveau de puissance garantizado / Niveau de puissance
l’épreuve de conformité Organisme agrée acoustique fixé acoustique garanti

Annex VI / Anhang VI TUV 91 dB(A) 97 dB(A)

Anexo VI / Annexe VI Süddeutschland Bau
und Betrieb GmbH
(0036)
Westendstr. 199
D-80686 Munchen

and has been produced in accordance with the following standards:

und in Übereinstimmung mit folgenden Richtlinien hergestellt worden ist:
y ha sido fabricado en conformidad con las siguientes normas:
et a été produit conforme aux dispositions des directives européennes ci-après :

2000/14/EC
89/336/EEC
98/37/EEC
William Lahner Dan Domanski
Vice President of Engineering Manager, Product Engineering
10.04.06
Date / Datum / Fecha / Date WACKER CORPORATION

2006-CE-LTC4L_Q.fm
Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90
Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957
Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21